Integration of devices and electrical connections in components or structural parts of polymeric material installed on a vehicle

Abstract

The invention relates to a method for the manufacturing of a component or a structural part made of polymeric material, adapted to integrate electrical devices and connections, and a system for carrying out the method. The method includes injection moulding of a composite material including: a non-conductive polymeric matrix; a dispersed phase including at least one carbonization promoter to form carbonaceous conductive structures; and a reinforcing-fibre filler to direct the distribution and orientation of the dispersed phase in the polymeric matrix, wherein injection of the composite material into a mould for forming the component or the structural part includes supplying the material in a spatially more-concentrated way at pre-established regions of the component or of the structural part designed for the incorporation of electrical devices or connections, and supplying the material in a spatially more spread-out way elsewhere.

What is claimed is: 
     
         1 . A method for manufacturing a component or a structural part made of polymeric material adapted to integrate electrical devices and connections, particularly for installation on-board a vehicle, including the injection moulding a composite material comprising:
 a non-conductive polyolefin-based polymeric matrix;   a dispersed phase including at least one promoter of carbonization adapted to form carbonaceous conductive structures; and   a reinforcing fibre filler adapted to direct the distribution and orientation of said dispersed phase in said polymeric matrix,   in which the injection of said composite material into a mould arranged for forming said component or said structural part includes supplying said material in a spatially more-concentrated way at pre-established regions of the component or of the structural part designed for the incorporation of electrical devices or connections formed by carbonaceous conductive structures in said composite material, and supplying said material in a spatially more spread-out way elsewhere.   
     
     
         2 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material is carried out at a temperature of the material of between 190° C. and 260° C. 
     
     
         3 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material is carried out with a temperature-regulation of the mould between 50° C. and 70° C. 
     
     
         4 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material is carried out with an injection velocity of between 60 cm 3 /s and 150 cm 3 /s. 
     
     
         5 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material is carried out at an injection pressure of between 60 bar and 80 bar. 
     
     
         6 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material includes a cooling time in the mould of between 30 s and 60 s. 
     
     
         7 . The method as set forth in  claim 1 , wherein the injection moulding of said composite material includes a holding phase at a holding pressure of between 35 bar and 60 bar. 
     
     
         8 . System for manufacturing a component or a structural part made of polymeric material, adapted to integrate electrical devices and connections, particularly for installation on-board a vehicle, including a mould arranged for forming said component or said structural part by injection moulding a composite material, comprising:
 a non-conductive polymeric matrix;   a dispersed phase including at least one promoter of carbonization adapted to form carbonaceous conductive structures; and   a reinforcing-fibre filler adapted to direct the distribution and orientation of said dispersed phase in said polymer matrix,   wherein said mould is assigned a first, spatially more-concentrated distribution of injection nozzles is associated with said mould at pre-established regions of the component or of the structural part designed for the incorporation of electrical devices or connections formed by carbonaceous conductive structures in said composite material, and a second, spatially more spread-out distribution of injection nozzles is associated with said mould elsewhere.   
     
     
         9 . The system as set forth in  claim 8 , wherein said first arrangement of injection nozzles includes a plurality of nozzles arranged at a distance not greater than 30 cm from one another and from the region designed for the manufacturing of electrical devices or connections. 
     
     
         10 . A method for manufacturing a component or a structural part of a vehicle, comprising a substrate of polymeric material integrating electrical devices and connections, including the steps of:
 providing a composite material, including:
 a non-conductive polymeric matrix; 
 a dispersed phase including at least one promoter of carbonization adapted to form carbonaceous conductive structures; and 
 a reinforcing-fiber filler adapted to direct the distribution and orientation of said dispersed phase in the polymer matrix, 
   injecting said composite material into a mold for forming the component or the structural part,   irradiating a laser beam on predetermined areas of said substrate of the formed component or structural part in such a way as to cause by carbonization the formation of carbonaceous conductive structures, resulting in an improved electrical conductivity of said areas, and to define conductive traces incorporated in the polymeric matrix and adapted to make electrical connections or electrical piezo-resistive devices, and   co-moulding on said substrate at least one metal terminal for electrical connection to at least one end of said conductive traces at an edge of said substrate, for connection with external signal distribution circuits.